4BD1-TRBG LIGHT REPAIR

TABLE OF CONTENTS
Page No Page No

Turbocharger .................................................................. 52
Bleeding the Fuel System............................................... 55
Fuel System Specifications............................................. 56
Fuel System Fault Finding .............................................. 57

Engine..................................................................................

Engine Front Mounting....................................................17

Exhaust Manifold.............................................................18
Air Inlet Manifold .............................................................19
Valve Clearance..............................................................21
Engine Sump...................................................................22
Engine Side Cover Plate Gaskets...................................23
Compression Test ...........................................................24
Engine System Specifications.........................................25
Engine Fault Finding .......................................................26
Cooling System....................................................................29
Fanbelt ............................................................................29
Thermostat ......................................................................29
Coolant............................................................................30
Water Pump ....................................................................31
Radiator...........................................................................33
Cooling System Specifications........................................34
Exhaust System...................................................................35
Exhaust System ..............................................................35
Fuel System.........................................................................37
Fuel Tank ........................................................................37
Fuel Lines – Low Pressure..............................................38
Fuel Lines – High Pressure.............................................40
Fuel Filter ........................................................................41
Fuel Sedimenter..............................................................42
Fuel Transfer Pump ........................................................42
Fuel Injection Pump ........................................................44
Fuel Injectors...................................................................46
Engine Stop Motor ..........................................................47
Hand Throttle Cable ........................................................49
Accelerator Cable............................................................50
Idle Speed and Accelerator Cable Adjustment ...............51

1
 Power Steering Pump................................................... 164

Electrical............................................................................

Glow Plugs ................................................................... 170

Starter Motor................................................................. 170
Alternator and Vacuum Pump ...................................... 171

2
 LIST OF FIGURES
Page No Page No
Figure 49 Bleeding the Fuel System..................................... 55

Figure 3 Engine Front Mounting (Left) ..................................17

Figure 4 Exhaust Inspection..................................................19
Figure 5 Exhaust Manifold Gasket Installation......................19
Figure 6 Exhaust Manifold Tightening Sequence .................19
Figure 7 Air Inlet Manifold Removal ......................................20
Figure 8 Air Inlet Manifold Gasket Installation.......................21
Figure 9 Timing Mark Alignment ...........................................21
Figure 10 Valve Adjustment First Sequence.........................22
Figure 11 Valve Adjustment Second Sequence....................22
Figure 12 Engine Sump Removal .........................................23
Figure 13 Rear Side Cover Plate Gasket Replacement........23
Figure 14 Alternator Adjusting Bolt .......................................24
Figure 15 Fanbelt Replacement............................................29
Figure 16 Thermostat Removal.............................................30
Figure 17 Fan, Spacer and Pulley.........................................31
Figure 18 Water Pump Gasket Replacement .......................32

Figure 24 High Pressure Fuel Lines Removal ......................40

Figure 25 Clamp Plate Location............................................40
Figure 26 Fuel Filter Draining................................................41
Figure 27 Fuel Filter Removal ...............................................41
Figure 28 Fuel Sedimenter Removal ....................................42
Figure 29 Fuel Transfer Pump Removal ...............................43
Figure 30 Timing Mark Alignment .........................................44
Figure 31 Injection Pump Timing Mark .................................45
Figure 32 Injection Pump Removal .......................................45
Figure 33 Injection Pump Installation ....................................46
Figure 34 Engine Stop Cable Removal.................................47
Figure 35 Stop Cable Mounting ............................................48
Figure 36 Stop Motor Removal .............................................48

Figure 43 Turbocharger Heat Shield Removal......................52

Figure 44 Oil Supply Line and Return Line Removal ............53
Figure 45 Air Intake Hose Removal ......................................53
Figure 46 Coolant Supply and Return Lines Removal ..........53
Figure 47 Exhaust Pipe to Turbocharger Removal ...............54
Figure 48 Turbocharger to Manifold Removal.......................54

3
 Figure 171 Power Steering Pump Removal ....................... 165

Figure 176 Glow Plug Removal.......................................... 170

Figure 177 Alternator Removal........................................... 171

4
 LIST OF TABLES
Page No Page No

Table 5 Engine System Specifications..................................25

Table 6 Engine Fault Finding ................................................26
Table 7 Cooling System Specifications.................................34
Table 8 Fuel System Specifications ......................................56
Table 9 Fuel System Fault Finding .......................................57

5
Engine Front Mounting
19. Remove the engine front mounting as follows (Figure 3):

NOTE
The following procedure is applicable to both left-hand and right-hand mountings.
a. Place a suitable block of wood on a jack.
b. Position the jack under the sump.
c. Remove the bolts, nuts and washers securing the mounting and the earth strap (left-hand side only) to
the mounting brackets. Discard the washers.

When raising the engine using the jack, extreme care must be taken to prevent
damage to any pipes, hoses, wiring harnesses and the front exhaust pipe.
d. Raise the engine enough to enable the mounting to be removed and remove the mounting.

Figure 3 Engine Front Mounting (Left)

17
20. Installation. Install the engine front mounting as follows:

NOTE
The following procedure is applicable to both the left-hand and right-hand
mountings.
a. Position the new engine mounting between the two brackets.
b. Install the bolts and the earth strap (left-hand side only) to the chassis bracket.
c. Install the nuts and new washers to secure the mounting to the engine.
d. Carefully lower the jack and remove it from under the vehicle.
e. Securely tighten the mounting nuts and bolts.

Exhaust Manifold
21. Removal. Remove the exhaust manifold as follows:

a. Remove the turbocharger (Para 73).

b. Remove the nuts and bolts securing the exhaust manifold to the cylinder head.
c. Remove the exhaust manifold.
22. Cleaning and Inspection. Clean and inspect the exhaust manifold as follows:

a. Remove all trace of gasket material from the manifold and the cylinder head.
b. Inspect the exhaust manifold for cracks and/or damage (replace as necessary).
c. Ensure that the machined faces are flat and smooth with no burn tracks or warping of the manifold.
Replace the manifold if necessary.
d. Ensure that the cylinder head studs and manifold studs are not bent or damaged. Replace the studs as
necessary (Figure 4).

18
 Figure 4 Exhaust Inspection
23. Installation. Install the exhaust manifold as follows:
a. Position two new exhaust manifold gaskets on the cylinder head so that the word ‘TOP’ is toward the
manifold (Figure 5).

Figure 5 Exhaust Manifold Gasket Installation

b. Place the exhaust manifold over the gaskets, aligning the studs with the corresponding holes in the
manifold.
c. Secure the manifold in position with the nuts, flat washers, new lock washers and bolts and tighten
them finger-tight.
d. Check that each gasket is correctly positioned and not distorted.
e. Tighten the manifold retaining nuts and bolts to 16–25 N.m (12–19 lbf.ft) using the tightening
sequence as shown in Figure 6.

Figure 6 Exhaust Manifold Tightening Sequence

f. Install the turbocharger and related parts (Para 75).

Air Inlet Manifold

24. Removal. Remove the air inlet manifold as follows:
a. Clean the area around the inlet manifold using a suitable cleaning agent and blow it dry with
compressed air.
b. Remove the high pressure fuel lines (Para 53).
c. Disconnect and plug the fuel return line at the fuel filter.
d. Remove the main fuel lines from the fuel filter to the injection and transfer pump (Figure 7).

NOTE
Plug all openings in the injection pump and filter adapter following the removal of
the fuel lines to prevent the ingress of dirt.

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 Figure 7 Air Inlet Manifold Removal
e. Remove the stop cable mounting bracket from the inlet manifold.
f. Remove the two bolts securing the fuel filter assembly to the support bracket.
g. Remove the filter assembly from the vehicle.
h. Remove the two bolts securing the inlet pipe to the inlet pipe mounting bracket.
i. Remove the two bolts securing the air inlet pipe to the inlet manifold and cylinder head.
j. Loosen the two hose clamps securing the air inlet pipe to the turbocharger.
k. Remove the air inlet pipe. Plug the turbocharger.
l. Remove the nuts, washers and springs securing the inlet manifold to the engine and remove the
manifold.
m. Remove and discard the gasket.
25. Cleaning and Inspection. Clean and inspect the air inlet manifold as follows:
a. Remove all trace of gasket material from the manifold and cylinder head. Inspect the manifold for
cracks or damage. Replace the manifold if necessary.
b. Ensure that the machined face is flat and smooth with no warping or burn tracks. Replace the manifold
if necessary.
26. Installation. Install the air inlet manifold as follows:
a. Position a new manifold gasket on the cylinder head with the projection uppermost and toward the rear
of the engine (Figure 8).
b. Place the inlet manifold over the gasket.
c. Secure the manifold in position with the nuts, washers and spring. Tighten the nuts finger-tight.
d. Check that the gasket is correctly positioned and not distorted.
e. Tighten the nuts and bolts to 16–25 N.m (12–19 lbf.ft).
f. Install the air inlet tube and tighten the hose clamps.
g. Secure the tube to the inlet manifold and cylinder head with the two bolts.

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 Figure 8 Air Inlet Manifold Gasket Installation
h. Install the two bolts securing the inlet pipe to the inlet pipe mounting bracket.
i. Tighten the bolts securely.
j. Position the fuel filter assembly on the support bracket.
k. Install the two retaining bolts and tighten them securely.
l. Using new sealing washers, install the main fuel lines between the transfer pump, fuel filter and
injection pump.
m. Install the high pressure fuel lines (Para 54).
n. Install the stop cable bracket on the inlet manifold and adjust the cable (Para 66).
o. Using new sealing washers; connect the fuel return line to the fuel filter and tighten the banjo bolt
securely.
p. Bleed the fuel system (Para 76).

Valve Clearance
27. Adjustment. Adjust the valve clearance as follows:

To avoid the possibility of the engine firing, ensure that the stop control is
operated (ignition turned off).
a. Wash the area around the valve cover using a recommended cleaning agent and blow it dry with
compressed air.
b. Remove the three nuts securing the valve cover to the cylinder head and remove the cover.
c. Rotate the crankshaft by hand in the direction of rotation until the number four cylinder valves are on
the rock.
d. Align the timing mark on the crankshaft pulley with the calibration mark on the timing cover.
e. Number one cylinder is now on top dead centre (TDC) compression stroke (Figure 9).

Figure 9 Timing Mark Alignment

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 f. Check that the valve clearances for the valves are 0.4 mm (0.016 in) and adjust the clearances as
necessary (Figure 10).

Figure 10 Valve Adjustment First Sequence

g. To adjust the remaining valves, rotate the crankshaft by hand in the direction of rotation for one
complete revolution until the timing mark is aligned (Figure 9).
h. Check that the valve clearances for the valves are 0.4 mm (0.016 in) and adjust the clearances as
necessary (Figure 11).

Figure 11 Valve Adjustment Second Sequence

28. Reassembly. Reassemble the valve cover as follows:
a. Using a new valve cover gasket and retaining nut seals, install the cover.
b. Tighten the three nuts to 19 N.m (14 lbf.ft).

Engine Sump
29. Removal. Remove the engine sump as follows:
a. Clean the area around the sump using a suitable cleaning agent and blow it dry with compressed air.
b. Remove the sump drain plug and drain the oil into a suitable container.
c. Install the drain plug with a new sealing washer and tighten it securely.
d. Remove the bolts and nuts securing the sump to the engine block.
e. Remove the sump and the supporting plates (Figure 12).
f. Remove all trace of gasket material from the engine block and the sump.
g. Clean the sump thoroughly.
30. Installation. Install the sump as follows:
a. Position a new gasket on the sump.
b. Position a new gasket and the supporting plates over the rim of the sump.
c. Position the sump complete with the gaskets and supporting plate on the engine block.
d. Install the retaining bolts and nuts and tighten them to 10–20 N.m (8–15 lbf.ft).

22
 e. Fill the engine with clean engine oil to the correct level.

Figure 12 Engine Sump Removal

Engine Side Cover Plate Gaskets

31. Rear Cover Plate Replacement. Replace the rear cover plate as follows:
a. Clean the area around the rear cover plate using a suitable cleaning agent and blow it dry with
compressed air.
b. Remove the two bolts and packing washers securing the rear cover to the engine block and remove the
rear cover (Figure 13). Discard the sealing washers.

Figure 13 Rear Side Cover Plate Gasket Replacement

c. Remove and discard the gasket.
d. Remove all trace of gasket material from the engine block and the rear cover.
e. Position a new gasket on the rear cover and new packing washers on the retaining bolts.
f. Install the rear cover and tighten the retaining bolts to 16–27 N.m (12–20 lbf.ft).
32. Front Cover Plate Replacement. Replace the front cover plate as follows:
a. Loosen the alternator mounting bolts and remove the adjusting bolt (Figure 14).
b. Remove the fanbelt from the alternator drive pulley.
c. Swing the alternator away from the engine.
d. Remove the two bolts securing the front cover to the engine block.
e. Remove the front cover.
f. Remove and discard the gasket.
g. Remove all trace of gasket material from the engine block and the front cover.

23
 Figure 14 Alternator Adjusting Bolt
h. Discard the packing washers fitted to the bolts.
i. Position a new gasket on the front cover and new packing washers on the retaining bolts.
j. Install the front cover and tighten the retaining bolts to 16–27 N.m (12–20 lbf.ft).
k. Install the fanbelt on the alternator drive pulley and adjust it (Para 36).

Compression Test
33. Procedure. Carry out the compression test as follows:
a. Apply the handbrake.
b. Start the engine.
c. Stop the engine when it reaches normal operating temperature.
d. Remove the in-line fuse located in the stop motor wiring harness, adjacent to the brake master
cylinder.

Operate the ignition switch prior to continuing to ensure that the vehicle will
not start.
e. Disconnect the wiring harness connected to the glow plug link strip.
f. Remove the nuts and washers securing the link strip to the glow plugs.
g. Using a 12 mm deep socket, remove the glow plugs.
h. Install the adapter (Table 3, Serial 1) into the first cylinder by using a 17 mm deep socket and fit the
compression gauge (Table 3, Serial 1).
i. Using the starter, crank the engine four to five revolutions and note the reading on the compression
gauge.
j. Note the reading and repeat the procedure for the remaining cylinders.
k. The compression pressure for each cylinder must be between 22 kg/cm2 (313 psi) and 30 kg/cm2
(441 psi) with a maximum variation of 5 kg/cm2 (71 psi) between cylinders.
l. Remove the compression gauge and adapter from the cylinder head.
m. Install the glow plugs and torque them to 22–27 N.m (16–20 lbf.ft).
n. Position the electrical strip link on the glow plugs and tighten the retaining nuts securely.
o. Connect the wiring harness to the glow-plug link strip.
p. Install the in-line fuse adjacent to the brake master cylinder.
q. Ensure the engine starts.

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Engine System Specifications
34. The engine system specifications are listed in Table 5.
Table 5 Engine System Specifications
Serial Specification Measurement
1 Air inlet manifold to cylinder head tightening torque 16–25 N.m (12–19 lbf.ft)
2 Exhaust manifold to cylinder head tightening torque 16–25 N.m (12–19 lbf.ft)
3 Rocker shaft tightening torque 20–30 N.m (15–22 lbf.ft)
4 Valve clearance inlet and exhaust 0.4 mm (0.016 in.)
5 Valve cover tightening torque 19 N.m (14 lbf.ft)
6 Engine oil pan (sump) tightening torque 10–20 N.m (8–15 lbf.ft)
7 Engine side covers tightening torque 16–27 N.m (12–20 lbf.ft)
8 Fanbelt deflection 10–15 mm
9 Transfer pump fuel delivery pressure 176–245 kPa
2
10 Compression pressure 22–30 kg/cm (313–441 psi)
2
[maximum variation 5 kg/cm (71 psi)]
11 Glow plug torque 22–27 N.m (16–20 lbf.ft)

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Engine Fault Finding
35. The procedures for engine fault finding are detailed in Table 6.
Serial Symptom
1 Engine misfiring
2 Engine stalls at low
speeds
3 Engine will not reach
no-load governed speed
Table 6 Engine Fault Finding
Probable Cause
Poor quality fuel, water or dirt in
fuel
Air in fuel system
Broken or leaking high pressure
fuel lines
Restriction in fuel lines or return
lines
Low fuel supply pressure
Improper valve adjustment
Defective fuel injection nozzle or
fuel injection pump
Engine improperly timed
Cylinder head gasket leakage
Idle speed too low
Fuel tank vent blocked or
partially blocked
Low fuel supply
Injection pump overflow valve
leaking, stuck open or closed
Air in fuel system
Accelerator linkage loose or out
of adjustment
Restricted fuel lines or stuck
overflow valve
High idle speed incorrect
Blocked in–line filter
Action
Drain sedimenter. Drain and flush the fuel tank. Install
new filters and fill tank with clean diesel fuel
Check the system for air leaks. Air will generally enter
the fuel system on the suction side of the transfer pump
Check for fuel leaks and replace defective parts
Check for fuel flow. If no flow, replace lines
Check that there is fuel in the fuel tank. Look for leaks,
sharp bends or kinks in the fuel line between fuel tank
and transfer pump. Check for a clogged or perforated
suction pipe in the tank or a blocked fuel suction hose.
Look for air in the system. Check fuel pressure, if much
less than the specified figure of approx 176–245 kPa
change the filter and recheck. If still low, replace the
transfer pump. Check that the overflow valve is operating
Check valve clearance, adjust to specification
Run the engine at a speed that gives maximum misfiring
or rough running. Loosen the high pressure fuel line
nuts, one at a time, on the injection pump cutting the fuel
flow to the cylinder.
NOTE
When fuel is cut from a given cylinder and running speed
does not change, it is an indication that the cylinder is
not firing. If however, no fuel is evident when the nut is
Loosened off, it is an indication that the injection pump is
defective
Check and adjust timing
Check for visible signs of leakage e.g. coolant in the
engine oil or oil traces in the coolant
Check the idle setting (650 ±20 rpm) and make the
necessary adjustments
Check the vent and hose, if blocked, replace
Check that there is fuel in the tank. Look for leaks, sharp
bends or kinks in the fuel supply lines. Check for air in
the fuel system. Drain the sedimenter. Check that fuel
pressure is approx 176–245 kPa. If not, replace the fuel
filter and recheck the pressure. If still low replace the
transfer pump
Repair or replace valve
Check the fuel system for air leaks. Air will generally get
into the fuel system on the suction side of the transfer
pump
Check all linkages and make the necessary repairs
Check flow in the fuel lines. Check the overflow valve for
a defective spring, worn valve, and valve setting or
sticking. Make all necessary repairs
Replace injection pump
Clean or replace filter

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 Table 6
Serial Symptom
4 Erratic engine speed
5 Low power
NOTE
When diagnosing low power
complaints, it is possible the
trouble can be traced to
chassis components, other
than the engine. Make sure
the vehicle rolls freely when
the brakes are released
6 Excessive engine vibration
7 Excessive black or grey
smoke
8 Excessive blue or white
smoke
9 Excessive fuel consumption
10 Excessive oil consumption
Engine Fault Finding (Continued)
Probable Cause
Air leaks in fuel suction line
Accelerator linkage loose or out
of adjustment
Restrictions in the air intake
system: clogged air filter
Damage or restrictions in the
accelerator or stop cable linkage
Low fuel pressure.
Excessive valve clearance
Blocked in–line filter
Crankshaft pulley loose
Fan blade not in balance
Engine mountings are loose,
worn or defective
Misfiring or running rough
Insufficient air for combustion
High exhaust back pressure
Faulty injection nozzle
Improper engine timing
Engine lubricating oil level too
high
Engine misfiring or running
rough
Worn engine components
Restrictions in air induction
system
External fuel system leakage
Faulty injection nozzle
External oil leaks
Clogged engine breather pipe
Excessive exhaust back
pressure
Worn engine components
Action
Check for air leaks and correct as necessary
Check all accelerator linkages and make the
necessary adjustments
Check the air pressure in the air inlet manifold.
Replace the air cleaner elements
Check the linkages, adjust to obtain sufficient
travel
Check the fuel supply lines for leaks, kinks or
restrictions. Also check for air in system. Check
fuel pressure, if low, replace the fuel filter and
recheck the pressure. If still low replace the
transfer pump. Also check for sticking, binding or
defective fuel overflow valve. Repair or replace as
necessary
Adjust valve clearance to specification
Clean or replace filter
Tighten pulley retaining bolt
Loosen or remove fanbelt and operate the engine
for a short time at the speed that the vibration was
present. If the vibration disappears, replace the fan
assembly
Tighten all mounting bolts. Install new components
as required
Refer to Serial 1
Replace air filter element
Check for faulty exhaust piping or muffler
obstruction. Repair or replace defective parts
Isolate faulty nozzle and report. Refer Serial 1
Check the timing and make the necessary
adjustments
Remove excess lubricating oil. If oil is
contaminated with either fuel or coolant,
completely drain the system and replace the oil
filter. Locate and rectify the source of the leak.
Refill with clean engine oil (8.5 litres), then check
level with dipstick after running the engine for
several minutes. DO NOT overfill
Refer to Serial 1
Report condition
Inspect system and remove restrictions
Check fuel system piping for signs of fuel leakage.
Repair or replace as necessary
Isolate faulty nozzle and report. Refer Serial 1
Check the engine for visible signs of oil leaks.
Check the front and rear crankshaft oil seals,
check gaskets and sump drain plug
Clean the pipe to remove the obstruction
Check the exhaust pressure and make necessary
corrections
Report condition
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 Table 6 Engine Fault Finding (Continued)
Serial Symptom Probable Cause
11 Engine overheats Coolant level low
Loose or worn fanbelt
Air flow through radiator
restricted
Radiator pressure cap defective
Defective thermostat or
temperature gauge
Combustion gases in coolant
Blocked oil cooler
Defective water pump
Incorrect driving techniques
12 High exhaust temperature Operating the vehicle in the
wrong gear ratio for load, grade
and altitude
Restriction in air induction
system
Air leaks in air induction system
Fuel injection timing incorrect
Restriction in the exhaust
system
Incorrect valve clearance
Defective injection nozzle
13 Oil in cooling system Defective oil cooler core
Failed head gasket
14 Low lubricating oil pressure Insufficient oil, oil leaks
Incorrect engine oil
Defective oil pump
Dirty oil filter
15 Coolant in lubricating oil Defective oil cooler core
Failed head gasket
16 Low compression Incorrect valve clearance
Failed head gasket
Broken or weak valve spring
Burned valves or seals
28
Action
Determine the cause. Replace leaking gaskets and
hoses. Tighten connections and add coolant
Adjust or replace
Remove all obstructions from outer surface or
radiator
Check the pressure release of radiator cap
103 kPa (14 psi). Replace if necessary
Check the opening temperature and for correct
installation of the thermostat. Replace as
necessary. Check operation of the temperature
gauge. Repair or replace as necessary
Report condition
Report condition
Replace the pump
Advise driver
Select the appropriate gear ratio
Inspect the system and remove restrictions.
Replace parts as necessary
Check pressure in the air intake manifold. Check
for restrictions at the air cleaner. Make necessary
corrections
Report condition
Inspect the system. Repair or replace as
necessary
Adjust valves to specified clearance
Isolate the defective nozzle assembly and replace
Report condition
Report condition
Check the oil level: add oil as required. Check for
oil leaks, repair or report
Drain the lubricating oil. Change the filters and refill
with clean engine oil. Check the level on the
dipstick. DO NOT overfill
Repair or replace as necessary
Check the operation of the by–pass valve for the
filter. Install new filter element. Drain engine oil and
refill with clean engine oil (8.5 litres)
Report condition
Report condition
Adjust valves to specified clearance
Report condition
Report condition
Report condition
COOLING SYSTEM

Fanbelt
36. Replacement. Replace the fanbelt as follows:
a. Loosen the alternator mounting bolts and remove the adjusting bolt (Figure 15).
b. Detach the fanbelt from the alternator drive pulley.
c. Remove the fanbelt from the crankshaft and water pump drive pulleys.
d. Install a new fanbelt.

NOTE
Ensure that the fanbelt is located in all three drive pulleys.
e. Swing the alternator away from the engine.

Figure 15 Fanbelt Replacement

f. Check the tension of the belt by applying moderate thumb pressure to the longest span of the belt.
g. When a belt deflection of 10–15 mm has been obtained, install and tighten the adjusting bolt and the
mounting bolts.
h. Start and run the engine for approximately 20 minutes.
i. Stop the engine and recheck the belt deflection.
j. Readjust as necessary.

Thermostat
37. Removal. Remove the thermostat as follows:
a. Clean the area around the thermostat housing using a suitable cleaning agent and blow it dry with
compressed air.
b. Loosen a clamp on the bottom radiator hose.
c. Disconnect the hose and drain approximately four litres of coolant into a suitable clean receptacle.

29
 NOTE
It may be necessary to loosen the expansion tank pressure cap to increase the flow of
coolant.
d. Reconnect the hose and tighten the hose clamp.
e. Loosen the hose clamp securing the top radiator hose to the thermostat housing.
f. Remove the hose from the housing.
g. Remove the three bolts securing the cover to the thermostat housing and remove the cover.
h. Remove and discard the gasket.
i. Lift out the thermostat.
j. Remove all trace of gasket material from the thermostat housing and the cover.
k. Inspect for corrosion, wear or damage. Repair or replace parts as necessary.
38. Installation. Install the thermostat as follows:
a. Install a thermostat of the correct temperature range (82ºC).
b. Position a new gasket on the housing.
c. Position the water outlet on the housing and install the three bolts.
d. Tighten the bolts securely.
e. Install the top hose onto the water outlet and tighten the top hose clamp securely.
f. Refill the cooling system (Para 39).

Coolant
39. Refilling Procedure. Refill the coolant system as follows:
a. Remove the brass filler plug from the thermostat housing (Figure 16).
b. Remove the expansion tank pressure cap.
c. Move the heater controls to the highest temperature position.

Figure 16 Thermostat Removal

d. Using coolant with a mixture ratio of 1:12 of Nalcool to water, top up the system through the filler
hole, then install the plug.
e. With the pressure cap removed, run the engine for a minimum of two minutes.
f. Stop the engine and remove the plug from the thermostat housing.
g. Top up as required and replace the plug.
h. Fill the expansion tank to the correct level and replace the cap.
i. Run the engine and check for leaks.

30
Water Pump
40. Removal. Remove the water pump as follows:
a. Clean the area around the water pump using a suitable cleaning agent and blow it dry with compressed
air.
b. Loosen the bottom radiator hose securing clamp and drain the coolant into a suitable clean receptacle.
c. Install the hose and tighten the securing clamp.

NOTE
The water pump must be replaced if any bearing noise is present and there is
excessive end float or radial movement.
d. Loosen the alternator mounting bolts and remove the adjusting bolt (Figure 15).
e. Detach the fanbelt from the alternator drive pulley.
f. Remove the screws and washers securing the fan shroud and move the shroud.
g. Remove the four bolts securing the water pump drive pulley to the water pump.
h. Remove the fan, spacer and pulley (Figure 17).

Figure 17 Fan, Spacer and Pulley

i. Loosen the hose clamps securing the bypass and heater hoses to the water pump.
j. Remove the hoses (Figure 18).

31
 Figure 18 Water Pump Gasket Replacement

NOTE
As the water pump retaining bolts are different lengths, note their respective
positions on removal.
k. Remove the bolts securing the water pump.
l. Remove the water pump from the vehicle.
m. Remove the screws securing the rear cover to the water pump.
n. Remove and discard the gasket.
41. Cleaning and Inspection. Clean and inspect the water pump as follows:
a. Remove all trace of gasket material from the water pump and engine block surfaces.
b. Inspect the water pump cover and housing for cracks, nicks, burrs or damage.
c. Inspect the housing for warping and check that the bearings rotate smoothly.
d. Replace the water pump as necessary.
42. Installation. Install the water pump as follows:
a. Using a new gasket and a liquid sealer, secure the rear cover to the water pump.
b. Tighten the screws securely.
c. Install the water pump retaining bolts in the positions noted on removal.
d. Using a new gasket and a suitable sealer, install the water pump and tighten the bolts to
44 N.m (32 lbf.ft).
e. Install the drive pulley, spacer and fan, then tighten the four bolts securely.
f. Install the fan shroud and secure it with the screws and washers.
g. Connect the bypass and heater hoses and tighten the hose clamps securely.
h. Install the fan belt (Para 36).
i. Fill the cooling system (Para 39).

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Cooling System Specifications
46. The cooling system specifications are detailed in Table 7.
Table 7 Cooling System Specifications
Serial Specification Measurement
1 Fanbelt deflection 10–15 mm
2 Thermostat opening temperature 82ºC
3 Water pump impeller to body clearance 0.3–0.8 mm
4 Water pump tightening torque 44 N.m (32 lbf.ft)
5 Pressure cap opening pressure 103 kPa (14 psi)

34
Fuel Lines – High Pressure
53. Removal. Remove the fuel lines as follows:
a. Clean the area around the high pressure fuel line that is to be removed and blow it dry with
compressed air.
b. Crack open the nut securing the line to the injector to relieve residual pressure and then loosen the nut
completely (Figure 24).

Figure 24 High Pressure Fuel Lines Removal

c. Loosen the nut securing the fuel line to the injector pump.
d. Remove the clamp plates retaining the fuel line (Figure 25).
e. Remove the high pressure fuel line through the inlet manifold.
f. Install suitable plugs into the injector pump and injectors.

Figure 25 Clamp Plate Location

54. Installation. Install the fuel lines as follows:
a. Install the high pressure fuel line, ensuring the line ends are seated correctly in the injector and the
injector pump connectors.
b. Tighten the fuel line connecting nuts to 28–31 N.m (21–23 lbf.ft).
c. Install and tighten the clamp plates securely.
d. Bleed the fuel system (Para 76).

40
Fuel Filter
55. Replacement. Replace the fuel filter as follows:
a. Clean the area around the fuel filter using a suitable cleaning agent and blow it dry with compressed
air.
b. Place a suitable container below the filter body; then loosen the overflow valve (Figure 26).

Figure 26 Fuel Filter Draining

c. Using a suitable filter removing tool, remove the fuel filter (Figure 27).

Figure 27 Fuel Filter Removal

d. Inspect the filter housing surface to ensure that the rubber seal has not become detached from the
filter.
e. Check the cover for signs of cracks or distortion and replace as necessary.
f. Check the threaded insert fitted to the cover and ensure that it is secure.
g. Smear clean fuel on the filter body rubber seal and install the filter on the cover.
h. Tighten the filter by hand until the rubber seal touches the cover face and tighten it one-half turn
further.

41
 i. Bleed the fuel system (Para 76).

Fuel Sedimenter

NOTE
The removal and installation procedures apply to both the left and right-hand side
fuel sedimenters.
56. Removal. Remove the fuel sedimenter as follows:
a. Clean the area around the sedimenter using a suitable cleaning agent and blow it dry with compressed
air.
b. Remove and plug the fuel lines from the sedimenter.
c. Remove the drain plug and drain the contents into a suitable container (Figure 28).

Figure 28 Fuel Sedimenter Removal

d. Remove the two bolts securing the sedimenter to the chassis bracket.
e. Remove the sedimenter.
57. Installation. Install the fuel sedimenter as follows:
a. Position the sedimenter on the chassis bracket and secure it with the two bolts.
b. Remove the plugs and install the supply and return lines and tighten them securely.
c. Tighten the drain plug.
d. Bleed the fuel system (Para 76).

Fuel Transfer Pump

58. Test Procedure. Test the fuel transfer pump as follows:
a. Prior to disconnecting any fuel pipes, clean the area around the transfer pump using a suitable cleaning
agent and blow it dry with compressed air.
b. Disconnect the fuel outlet pipe from the fuel transfer pump.
c. Connect a T-connector between the transfer pump and the fuel outlet pipe.
d. Connect the pressure gauge.
e. Bleed the air from the fuel system (Para 76).
f. Start the engine and check that the fuel pressure indicated is 175–245 kPa (25–35 psi).
g. Stop the engine.

42
 h. If the pressure is less then specified, remove the in-line fuse located in the stop motor wiring harness
adjacent to the brake master cylinder.

Removal of the in-line fuse may not prevent the engine from starting. Ensure
an operator has full control of the vehicle before proceeding to the next step to
prevent injury to personnel and damage to the vehicle and / or the facility.
i. Using the ignition switch, crank the engine to check that it does not start.
j. Remove the T-connector and connect the pressure gauge directly to the transfer pump outlet.
k. Crank the engine for four to five turns and check the pressure on the gauge.
l. If the pressure shown is 333–412 kPa (48–60 psi), the pump is functioning correctly, indicating that
the overflow valve is the cause of the initial low pressure and requires replacement.
m. Crack loose the gauge connection at the transfer pump to allow the fuel (under pressure) to bleed off.
n. Remove the gauge and using new sealing washers, install the pipe on the transfer pump outlet.
o. Tighten the banjo bolt securely.
p. Bleed the fuel system (Para 76).
q. Connect the in-line fuse to the stop motor.
59. Removal Remove the fuel transfer pump as follows:
a. Loosen the fuel line from the filter cover to the pump at the filter.
b. Loosen the clamp securing the two lines (Figure 29).

Figure 29 Fuel Transfer Pump Removal

c. Remove the two fuel lines from the pump and plug them with suitable plugs. Discard the sealing
washers.
d. Remove the three nuts and spring washers securing the transfer pump to the injection pump. Discard
the spring washers.
e. Remove the pump.
f. Remove and discard the O ring.

43
60. Installation. Install the fuel transfer pump as follows:
a. Using a new O ring, install the transfer pump on the injection pump.
b. Secure the transfer pump with the three nuts and new spring washers. Tighten the nuts evenly.

NOTE
An in-line filter is fitted to the inlet line banjo bolt on the transfer pump. The bolt
head is marked with an arrow. Ensure the filter is clean and the arrow aligns with the
fuel line on installation.
c. Remove the plugs from the fuel lines.
d. Using new sealing washers, install the two banjo bolts and tighten them securely.
e. Tighten the banjo bolt securing the fuel line to the filter adapter and tighten the pipe clamp.
f. Bleed the fuel system (Para 76).

Fuel Injection Pump

61. Removal. Remove the fuel injection pump as follows:
a. Disconnect the battery.
b. Wash the area around the injection pump using a suitable cleaning agent and blow dry with
compressed air.
c. Disconnect the crankcase breather pipe connected to the air inlet tube.
d. Remove the inlet manifold (Para 24).
e. Disconnect the accelerator cable from the pump control lever.
f. Remove the four nuts and eight washers securing the oil filter housing and remove the oil filter
housing complete with the filters. Discard the spring washers.
g. Disconnect and plug the fuel supply and return lines.
h. Remove and plug the oil feed pipe from the injection pump.
i. Remove the injection pump rear mounting bracket.
j. Rotate the crankshaft by hand in a clockwise direction, to align the crankshaft pulley and the TDC
mark on the timing cover (Figure 30) with the number one cylinder at TDC.

Figure 30 Timing Mark Alignment

k. With the TDC mark aligned, remove the inspection plate on the timing cover and ensure that the
notched line is aligned with the arrow mark (Figure 31).

44
 Figure 31 Injection Pump Timing Mark
l. If the arrow mark does not align with the notched line, rotate the crankshaft a further 360 degrees.

NOTE
Do not rotate the engine once the timing mark is aligned.
m. Remove the timing cover plug.
n. Remove the seven injection pump mounting bolts (Figure 32).
o. Withdraw the injection pump.

Figure 32 Injection Pump Removal

62. Installation. Install the fuel injection pump as follows:
a. Remove the valve cover.
b. Rotate the crankshaft by hand in the direction of rotation, until the number one cylinder is approaching
TDC on the compression stroke and the number four cylinder valves are on the rock.
c. Continue to turn the crankshaft until the notched line on the crankshaft pulley is aligned with the 12
degree mark on the timing case.

NOTE
This is only a reference setting as the timing is set at TDC.
d. Align the pump advance notched line towards the mounting flange notched line; then rotate the pump
clockwise until spring tension is felt.
e. Install a new flange gasket and the pump; then check that the advance line is approximately 5 mm
below the pointer on the timing case aperture (Figure 33).

45
 Figure 33 Injection Pump Installation
f. Align the notched line on the pump with the notched line on the mounting flange.
g. Secure the pump with one bolt to prevent radial movement.
h. Rotate the crankshaft by hand in the direction of rotation, until the TDC mark on the crankshaft pulley
aligns with the timing mark on the timing case. The advance line should now be in line with the
pointer (Figure 30).
i. Install the remaining bolts and tighten them securely.
j. Install the valve cover and tighten the retaining bolts securely.
k. Install the plug and inspection cover onto the timing case.
l. Using new sealing washers, install the oil feed pipe onto the injection pump and tighten the banjo bolt
securely.
m. Connect the fuel supply and return lines (Para 52).
n. Install the oil filter housing complete with the filters and secure it with the four nuts, flat washers and
new spring washers.
o. Connect the accelerator cable from the pump control lever.
p. Install the inlet manifold (Para 26).
q. Connect the crankcase breather pipe to the air inlet tube.
r. Connect the accelerator cable and adjust it (Para 70).
s. Bleed the fuel system (Para 76).
t. Reconnect the battery.

Fuel Injectors
63. Removal. Remove the fuel injectors as follows:
a. Wash the cylinder head area around the injectors and all the pipe connections with a suitable cleaning
agent and blow them dry with compressed air.
b. Remove the fuel return line from the injectors. Remove and discard the sealing washers.
c. Remove the high pressure fuel lines from the injectors. Plug the fuel lines with suitable plugs.
d. Remove the injector retaining nuts and spring washers. Discard the spring washers.

46
 Do not strike the injector tip on the cylinder head or on the rack as this can
damage the spray holes.
e. Carefully remove the injectors from the cylinder head and place them in a suitable rack in numerical
order, so that the injectors can be installed in the cylinders from which they were removed.

NOTE
To remove a stuck injector, apply penetrating oil around the injector body and
gradually extract the injector by inserting a suitable lever between the cylinder head
and injector body.
f. Remove and discard the dust cap and nozzle gasket.
g. After removing the injectors from the cylinder head, plug the injector cavities with a suitable plug to
prevent contaminants from falling into the cylinder.
64. Installation. Install the fuel injectors as follows:
a. Using a new dust cap and nozzle gasket, install the injectors in the cylinder head.
b. Install the nuts and new spring washers. Tighten the nuts to 20–30 N.m (15–22 lbf.ft).
c. Install the fuel return line and new sealing washers. Tighten the five banjo bolts securely.
d. Connect the high pressure fuel lines to the injectors.
e. Tighten the retaining nuts and clamps securely.
f. Bleed the fuel system (Para 76).

Engine Stop Motor

65. Removal. Remove the engine stop motor as follows:
a. Disconnect the battery.
b. Disconnect the stop cable end from the injection pump stop lever (Figure 34).
c. Disconnect the in-line fuse installed in the blue cable.
d. Disconnect the white multi pin connector from the stop motor.

Figure 34 Engine Stop Cable Removal

e. Remove the cable bracket from the inlet manifold (Figure 35).

47
 Figure 35 Stop Cable Mounting
f. Remove the locknuts securing the stop motor to the firewall (Figure 36).

Figure 36 Stop Motor Removal

g. Remove the stop motor complete with the stop cable from the vehicle.
66. Installation. Install the engine stop motor as follows:
a. Position the stop motor and cable assembly on the firewall and secure it with the two retaining nuts.
b. Install the cable bracket on the inlet manifold (Figure 35) and tighten the two bolts securely.
c. Connect the wiring harness to the motor.
d. Connect the battery.
e. Turn the ignition switch ‘ON’ to obtain the maximum length on the engine stop cable.
f. Connect the cable end to the stop lever.
g. Ensuring the stop lever is in the ‘ON’ position; adjust the stop cable to give approximately 1 mm free
play.
h. Turn the ignition ‘OFF’.

48
Idle Speed and Accelerator Cable Adjustment
71. Adjust the idle speed and accelerator cable as follows:
a. Start the engine and warm up to normal operating temperature.
b. Ensure the control lever is in contact with the idle set bolt when the accelerator pedal is in the ‘OFF’
position (Figure 40).

Figure 40 Accelerator Cable and Idle Speed Adjustment

c. Using a tachometer, check that the idle speed is 650 ±20 rpm.
d. Adjust as necessary by turning the stop bolt clockwise to increase engine idle speed and anticlockwise
to decrease engine idle speed.
e. Secure the locknut following the adjustment.
f. With the accelerator pedal still in the ‘OFF’ position, adjust the cable length as required to ensure the
stop lever is in contact with the stop bolt.
g. Increase the engine speed by operating the accelerator pedal and return it to the ‘OFF’ position.
h. Check that the pedal returns correctly and the engine idle speed remains at 650 ±20 rpm.
i. Fit a new split pin to the control lever clevis.

51
Turbocharger
73. Removal. Remove the turbocharger as follows:
a. Wash the area around the turbocharger and blow it dry with compressed air.
b. Remove the bolts securing the heat shield to the turbocharger and remove the heat shield (Figure 43).

Figure 43 Turbocharger Heat Shield Removal

c. Disconnect the oil supply line and the oil return line from the turbocharger (Figure 44).

52
 Figure 44 Oil Supply Line and Return Line Removal
d. Loosen the air intake hose clamp and slide the hose from the turbocharger (Figure 45).

Figure 45 Air Intake Hose Removal

e. Disconnect the coolant supply line and the coolant return line from the turbocharger (Figure 46).

Figure 46 Coolant Supply and Return Lines Removal

f. Remove the nuts securing the exhaust pipe to the turbocharger exhaust adaptor and remove the exhaust
pipe (Figure 47).

53
 Figure 47 Exhaust Pipe to Turbocharger Removal
g. Remove the nuts securing the turbocharger to the exhaust manifold and the two bolts securing the
exhaust adapter to the manifold. Carefully remove the turbocharger (Figure 48).

Figure 48 Turbocharger to Manifold Removal

74. Cleaning and Inspection. Clean and inspect the turbocharger as follows:
a. Remove all trace of gasket material from the turbocharger and exhaust manifold mating surfaces.
b. Inspect the turbocharger housing for cracks, burrs or warping and that the bearings rotate smoothly.
c. Replace the turbocharger if necessary.
75. Installation. Install the turbocharger as follows:
a. Position the new gasket and turbocharger on the exhaust manifold and loosely install the retaining
nuts.
b. Loosely install the two bolts securing the turbocharger exhaust adapter to the manifold but do not
tighten them at this stage.
c. Install the exhaust pipe to turbocharger nuts but do not tighten them at this stage.
d. Connect the oil supply line and tighten it to 12–16 N.m (8.8–11.6 lbf.ft).
e. Connect the oil return line and tighten it to 6–10 N.m (4.4–7 lbf.ft).
f. Connect the coolant supply line and the coolant return line and tighten the connections securely.
g. Tighten the turbocharger to exhaust manifold attaching nuts and the bolts securing the exhaust adapter
to 30–34 N.m (22–25 lbf.ft).
h. Install the air intake hose and air cleaner tube. Tighten the clamps securely.
i. Tighten the exhaust pipe to turbocharger nuts securely.
j. Start the engine and check for air and exhaust leaks and rectify as necessary.
k. Install the heat shield on the turbocharger and secure it with the three bolts.

54
Bleeding the Fuel System
76. Procedure. Bleed the fuel system as follows:
a. Loosen the screw cap on the transfer pump and operate the primer.
b. Loosen the overflow valve on the fuel filter adaptor and continue operating the primer until a solid
stream of fuel flows from the valve (Figure 49)

Figure 49 Bleeding the Fuel System

c. Tighten the overflow valve while operating the primer.
d. Loosen the air bleed screw and continue operating the primer until a solid stream of fuel flows from
the air bleed screw.
e. Tighten the air bleed screw.
f. Secure the primer screw cap.
g. Start the engine.
h. Ensure that the engine runs smoothly.

55
Fuel System Specifications
77. The fuel system specifications are detailed in Table 8.
Table 8 Fuel System Specifications
Serial Specification Measurement
1 High pressure fuel line nuts tightening torque 28–31 N.m (21–23 lbf.ft)
2 Fuel transfer pump plug tightening torque 78–88 N.m (57–64 lbf.ft)
3 Fuel transfer pump primer tightening torque 40 N.m (28 lbf.ft)
4 Fuel transfer pump adapter tightening torque 12 N.m (10 lbf.ft)
5 Fuel injection pump timing TDC
6 Fuel injector starting pressure 18 134 kPa (2 630 psi)
7 Fuel injector cap nut tightening torque 58–78 N.m (43–58 lbf.ft)
8 Fuel injector retaining nuts tightening torque 20–30 N.m (15–22 lbf.ft)
9 Engine idle speed 650 ±20 rpm
10 Air inlet manifold to cylinder head tightening torque 16–25 N.m (12–19 lbf.ft)
11 Turbocharger oil supply line tightening torque 12–16 N.m (8.8–11.6 lbf.ft)
12 Turbocharger oil drain pipe tightening torque 6–10 N.m (4.4–7.0 lbf.ft)
13 Turbocharger to exhaust manifold tightening torque 30–34 N.m (22–25 lbf.ft)

56
Fuel System Fault Finding
78. The procedures for fuel system fault finding are detailed in Table 9.
Table 9
Serial Symptom
1 Difficult starting
2 Irregular idle
3 Insufficient maximum speed
Fuel System Fault Finding
Probable Cause
Lack of fuel
Fuel contamination
Stop motor faulty
Incorrect starting procedure
Air in fuel system
Fuel restriction
Low cranking speed
Incorrect timing
Fuel return restricted
Fuel flow incorrect
Engine condition
Faulty injectors
Fuel tank breather blocked
High pressure fuel lines leaking
Injection pump faulty
Fuel transfer pump faulty
Air in fuel system
Fuel restriction
Fuel contamination
Incorrect timing
Fuel return restricted
Fuel flow incorrect
Engine condition
Faulty injectors
High pressure fuel lines leaking
Injection pump faulty
High pressure fuel line
restriction
Idle speed incorrect
Incorrect accelerator cable
adjustment
Engine vibration
Injection pump loose
Air in fuel system
Fuel restriction
Injection pump faulty
Incorrect accelerator cable
adjustment
Action
Check tank contents
Check fuel for water, dirt, wax or incorrect fuel
Check motor and cable adjustment
Check heater plugs, accelerator and stop cable
operations
Check all unions, lines and hoses. Bleed system
Check filters and supply lines
Check battery, starter, cables and engine oil type
Check timing
Check fuel return lines
Check fuel lines not crossed
Check cylinder compressions, valve timing and
clearances and air cleaner condition
Check injectors for correct type, starting pressures
and spray patterns
Check tank breather
Check and tighten lines
Replace injection pump
Replace transfer pump
Check all unions, lines and hoses. Bleed system
Check filters and supply lines
Check fuel for water, dirt, wax or incorrect fuel
Check timing
Check fuel return lines
Check fuel lines not crossed
Check cylinder compressions, valve timing and
clearances and air cleaner conditions
Check injectors for correct type, starting pressures
and spray patterns
Check and tighten lines
Replace injection pump
Check for kinks, bore reduction
Adjust idle speed
Adjust cable
Check engine mountings
Check and tighten mounting bolts
Check all unions, lines and hoses. Bleed system
Check filters and supply lines
Replace injection pump
Adjust cable
57
 Table 9 Fuel System Fault Finding (Continued)
Serial Symptom Probable Cause
Fuel transfer pump faulty
Incorrect timing
Faulty injectors
4 Irregular engine output Fuel restriction
Fuel transfer pump faulty
Air in fuel system
Fuel contamination
Injection pump faulty
Faulty injector
Incorrect timing
Faulty advance mechanism
Incorrect stop and accelerator
cable adjustment
5 Excessive smoke Fuel contamination
Incorrect timing
Engine condition
Injection pump fault
Faulty injector
Turbocharger wheel rubbing
Air leak between turbocharger
and cylinder head
Turbocharger turbine seal
leaking
6 Excessive knocking Incorrect starting procedure
(Detonation)
Faulty injector
Lack of coolant in radiator
Lack of oil in engine
Incorrect timing
Faulty advance mechanism
7 Maximum speed excessive Injection pump faulty
8 Engine will not shut down Stop motor or cable faulty
Injection pump fault
9 Low power Fuel rate low, fuel pressure
correct and turbocharger
pressure high. Air temperature
between 10ºC and 38ºC
10 Excessive crankcase gases Turbocharger seals leaking
(blow by)
58
Action
Replace transfer pump
Check timing
Check injectors for correct type, starting pressure
and spray patterns
Check filters and supply lines
Replace transfer pump
Check all unions, lines and hoses. Bleed the
system
Check fuel for water, dirt, wax or incorrect fuel
Replace injection pump
Check injector for correct type, starting pressure
and spray pattern
Check timing
Report
Check and adjust
Check fuel for water, dirt, wax or incorrect fuel.
Check timing
Check cylinder compressions, valve timing and
clearances and air cleaner condition
Replace injector pump
Replace injector
Replace turbocharger
Check for air leaks and rectify
Replace turbocharger
Check heater plugs
Replace injector
Check level
Check level and top up as necessary
Check timing
Report
Replace injection pump
Check motor and cable adjustment
Replace injection pump
Replace turbocharger
Replace turbocharger
Power Steering Pump
262. Removal. Remove the power steering pump as follows:
a. Place a suitable container under the power steering pump.
b. Remove the power steering pump reservoir cap.
c. Disconnect the low pressure hose from the power steering pump and drain the fluid into the container.
d. Disconnect the high pressure hose from the power steering pump.
e. Plug the high and low pressure hoses.
f. Remove the bolts securing the power steering pump to the timing gear and remove the pump
(Figure 171).

164
 Figure 171 Power Steering Pump Removal
g. Remove and discard the O ring and gasket. Plug all apertures on the power steering pump.
263. Installation. Install the power steering pump as follows:
a. Remove all trace of gasket from the pump and mating surfaces.
b. Using a new O ring and gasket, install the power steering pump-to-timing gear housing. Tighten the
bolts to 64 N.m (48 lbf.ft).
c. Connect the high and low pressure hoses to the power steering pump and tighten them securely.

Do not reuse the fluid drained from the reservoir.

d. Fill the power steering fluid reservoir and install the reservoir filler cap.
e. Bleed the power steering system.

165
Glow Plugs
270. Removal. Remove the glow plugs as follows:
a. Disconnect the battery.
b. Loosen the nuts securing the electrical strip link to the glow plugs and slide the link away
(Figure 176).
c. Remove the nut from No. 4 cylinder plug and remove the feed wire.
d. Using a 12 mm deep socket remove the glow plugs from the cylinder head.

Figure 176 Glow Plug Removal

271. Installation. Install the glow plugs as follows:
a. Install the glow plugs and torque them to 22–27 N.m (16–20 lbf.ft).
b. Position the electrical strip link on the glow plugs and secure it with new nuts at cylinders 1, 2 and 3.
c. Connect the electrical feed wire to cylinder No. 4 glow plug.
d. Secure the feed wire and strip link to the glow plug with a new nut.
e. Connect the battery.

Starter Motor
272. Removal. Remove the starter motor as follows:
a. Disconnect the battery.
b. Remove the nuts and washers securing the cables to the starter motor and solenoid.
c. Tag and remove the cables.
d. Remove the bolt, two nuts and lock washers securing the starter motor to the flywheel housing.
Discard the lock washers.
e. Remove the starter motor.
273. Installation. Install the starter motor as follows:
a. Install the starter motor and secure it in position with the bolt, two nuts and new lock washers.
b. Tighten the bolt and two nuts to 40 N.m (30 lbf.ft).
c. Install the cables and washers and tighten the nuts securely.
d. Connect the battery.

170
Alternator and Vacuum Pump
274. Removal. Remove the alternator and vacuum pump as follows:
a. Disconnect the battery.
b. Loosen the hose clamp securing the hose to the vacuum pump (Figure 177) and plug the hose with a
suitable plug.

Figure 177 Alternator Removal

c. Remove the banjo bolt and sealing washers securing the oil feed pipe to the vacuum pump. Discard the
sealing washers.
d. Remove and plug the pipe.
e. Loosen the hose clamp securing the oil return hose to the vacuum pump.
f. Remove and plug the hose.
g. Remove the nut and washer securing the cable to the B-terminal of the alternator.
h. Remove the field excitation plug from the alternator.
i. Loosen the alternator mounting bolts and remove the adjusting bolt.
j. Remove the fanbelt from the alternator drive pulley and swing the alternator away from the engine.
k. Remove the mounting bolts and remove the alternator.
275. Installation. Install the alternator and vacuum pump as follows:

NOTE
Prior to installation, apply a few drops of engine oil into the oil feed opening. Rotate
the alternator pulley to prevent oil starvation on initial starting.
a. Position the alternator on the mounting bracket and install the two mounting bolts. Do not tighten them
at this stage.
b. Move the alternator towards the engine and install the fanbelt.
c. Fit the adjusting bolt and move the alternator away from the engine until a belt deflection of 10–15
mm is obtained.
d. Tighten the adjusting and mounting bolts securely.

171
 e. Fit the field excitation plug to the alternator socket and the single cable to the alternator B-terminal.
f. Install the oil return hose to the vacuum pump and secure it with the hose clamp.
g. Install the pipe, new sealing washers and banjo bolt. Tighten the bolt securely.
h. Install the vacuum hose to the alternator and secure it with the hose clamp.
i. Connect the battery.

172